Production of buttons and like articles



Patented on. 26, 1937 T OFFICE PRODUCTION OF BUTTONS LIKE ARTICLES Peter C. Christensen, East Orange, N. J.

No" Drawing. Application July 16,

Serial No. 623,006

9 Claims. (01. 1s 4'z.5)'

My invention relates to the production of butto advantage instead of alum (aluminum potasslum sulphate).

tons and similar articles and more particularly to an improved method of producing such articles preferably from a material which is composed 5 principally of casein.

The principal object of my invention is to produce buttons or thelike from material of the character specified, either in solid colorsor in multi-tone or mottled effects, as desired, which will be at least equal and in many cases superior in color, appearance, toughness, durability and other qualities, to the majority of the buttons made in accordance with present practices from various materials, such as vegetable ivory, bakelite, casein, etc.,'now ge'nerally employed.

. Another object of my invention is to provide an improved and simple method which is adapted to effectively and economically produce buttons from such material, and which results in a. high output of finished buttons, an extremely low per-'- centage of rejections, and substantially no waste,

of the material from which the buttons are made.

' A still further object of my invention is to soproduce buttons from material of the character described, that they may be colored, either in solid tones or mottled efiects and preferably by theuse of naturalwood dyes, so eflectively and to such a depth that the color will endure and be substantially unaffected in the various operations to which the buttons are subjected subsequent to the dyeing or coloring thereof.

Another object of my invention is to provide an improved casein material which is peculiarly adapted for the production therefrom, in accordance with my improved method, of buttons having the desirable characteristics indicated above. I Other objects and features of my invention will be apparent or will occur tothose skilled in the art, from the following description and the appended claims.

The material from which buttons are made in accordance with my invention consists principally -of casein, and is preferably a suitable mixture of casein, water and alum (aluminum potassium sulphate). The casein employed may be any of those commercial forms known to the .trade as rennet casein, hydrochloric acid casein and acetic acid casein,-but I find that best results are obtained by using rennet casein; Also while I prealums, such as aluminum ammonium sulphate and aluminum sodium sulphate, may be employed .rods and a greater proportion for large rods.

twenty-four hoursup to amonthor more, de-

The commercial casein is in the form of a dry powder containing from 4% to 5% byweight of water. In forming the mixture or material re- 5 ferred to, the amount of water added may be from 10% to 25% by weight ofthe casein. The percentage of water added toobtain best results is-dependent somewhat on the diameter of the rods to be produced as hereinafter described, from 10 the mixture or composite casein material. For best results a lesser proportion of water should be added to the casein for the production of small For a. uniform mixture to be used for all sizes'of 5 rods, I find it prefer'ablato add an amount of water which is substantially 15% by weight of .the casein employed.

Where alum is mixed with the casein and water,- the amount of alum added may vary-from 1% to 5% by weight of the casein, but I preferably add substantially-2% by weight of the casein. In producing. the composite material, the

casein, water and alum are merely all introduced into an ordinary mixing machine and the latter isoperated until these substances are thoroughly commingled and a uniform mixture is obtained. This usually takes from 5 to 10 minutes. If'the buttons" or other articles to be produced are to be of a single solid color, a suitable dyeing material, or' where the flnished'articles are to be solid white, a white. pigment may be advantageously added at this point to the casein and other substances a'.nd mixedtherewith in the .mixing machine. The mixing operation may be carried on at ordinary room temperature.

The mixture produced as'just described, is in granular or rather coarse powder form, and is now highly compressed ina suitable extrusion press into a solid coherent material. This solid material as extruded from the press, is of 1miform cross section and is usually, though not necessarily, cylindrical. As it issues from the press the said material, which is fairly soft and flexible, 5 is cut into rods of any desired length, usually a 4 length of from three to four feet. The press I may be adjusted to produce cylindrical rods pending on when it is desired to use the rods for the production of the buttons or other articlesto be made therefrom. After being removed frdm the water, however, the rods should be kept where the air is of such humidity asto prevent the moisture in the rods from drying out to any 'This is important as will hereinafter appear.

Where buttons, for example, are tobe made in accordance with my invention the rods produced and treated as above described and while still in a relatively uncured condition, are usually each turned into a large number of blanks which substantially conform in size and shape to the finished buttons by a turning machine, preferably of the type disclosed in Patents Nos. 1,819,811 and 1,843,944, respectively granted August 18, 1931 and February 9, 1932 on applications of Emanuel Clemens, which automatically and very rapidly faces, edges, backs and cuts oil the blanks from the rod by successive turning cutting operations as described in said patents. Because buttons thus made directly "from the relatively uncured rods are produced byturning cutting operations only, each of such buttons is circular and is also of uniform shape in all it's radial cross-sections.

The shavings and the like produced in turning buttons to shape directly from the relatively uncured rods are not waste, for the same upon being dried and ground may be advantageously mixed with the raw commercial casein, in any quantity up to 50% by weight of the latter, and the resulting mixture may then have water and alum or other suitable material added thereto and combined therewith, as hereinbefore described, to

obtain the composite casein material'from which the relatively uncured rods, referred to above, are

produced.

The buttons or other articles when turned to shape from rods of relatively uncured material in the manner described above, are next cured to harden and toughen the same preferably by treatment with a formaldehyde solution. While, technically, proper curing of the buttons can be obtained by treating the same with a formaldehyde solution which may be anywhere from a 10% to a 20% solution, I find that best results are obtained, especially when the buttons are subsequently dyed, by using a solution of from 10% to 15% in strength. In any-event, when it is desired to obtain a uniform color effect in dyeing a given lot of buttons, the latter should be cured by treatment with formaldehyde solution of a. given and unvarying uniform strength. I preferably treat the buttons with a solution produced by mixing three parts, by volume, of watenwith one part of the ordinary 40% solution of form-- aldehyde gas, although as indicated, this issub- 'ject to considerable variation. If a stronger than the. strength indicated as preferable', eflective curing proceeds at the' rate of about 1% to 2 days per millimeter in thickness of thematerlal being treated.

Various processes have heretofore been suggested or employed for producing buttons from casein material. Some of these processes involve the cutting of the buttons from cured rods, while others involve the molding, of casein material when in an uncured or partially cured condition or agents. I believe I am the first to disclose a practical process of producing satisfactory buttons involving the turning of buttons in their final size and shape directly from relatively uncured lli rods of casein material and the subsequent curing of the buttons thus formed. In' this connection when shaped articles formed of substantially uncured or relatively uncured casein material are cured, as by subjecting them to the action 20 come deformed, this tendency'being particularly 2E pronounced in the case of comparatively thin articles such as buttons. 1 have found, however, that if each of a lot of substantially uncured or relatively uncured buttons or similar articles of casein material is circular and has a uniform 3i texture and distribution of the material thereof and if each of the buttons is of uniform shape in I all its radial cross-sections, then such button upon being cured will not be deformed, or, at

least, the deformation thereof will be so slight as 3! to be negligible. This is probably due to the fact that when substantially uncured or relatively uncured buttons or articles of casein material in respect of which the conditions just described prevail, are cured, the stresses set up therein as 44 the result of such curing are substantially balanced.

After being cured by immersion in formaldehyde solution as above described, the buttons are scoured in the usual manner by subjecting the 41 same at room temperature to the action of a mixture of pumice and sawdust, or the like, in a rotating drum. This scouring operation when effectively performed, takes about 24 hours.

The buttons are next drilled, preferably in an 5 automatic drilling machine to provide the same with the desired number and arrangement of holes. The drilled buttons are then preferably prepared for the finishing and polishing treatments (if they are white or of any solid color and 5, are notthereafter to be dyed) or for dyeing, finishing and,polishing (if they are still to be dyed), by drumming the same in the usual manner for a period of from 24 to 48 hours, with a mixture of powdered chalk, sawdust and bran, or other suit- 6 able mixture. This imparts a preliminary polish to the buttons.

After imparting such preliminary'polish to the buttons, the latter are subjected to further treatment which involves additional polishing there- 6 of, either mechanically or chemically according to the finish and appearance desired, and which" in case the buttons are their white and it is intended that when finished they shall be colored either in; a single tone or multi-tone effect, also involves 7 the dyeing of the buttons with suitable coal-taror natural dyes. v

In case the buttons upon being giventhe said preliminary polish, are to be finished by'mechanically polishing them and without being dyed, 7,

10 when combined with hardening and converting action of a finelythey are first subjected to the divided mixture of sawdust and bran, or other suitable material, in a rotating drum for a sui ficient period, generally from 24 to 48 hour's. The buttons are then introduced together with a quantity of small wax-coated wooden pegs into a rotatable tumbling machine and the latter is continuously operated fora hours. The buttons are polish, but

thus given a further while this polish is of sufficient body dull; Accordingly the buttons are now introduced into a tumbler drum together with unccated wooden pegs, and such drum is rotated continuously for, about 2 hours, This operation imparts a final bright polish to the buttons, which are now finished and need only to be sorted, inspected and packed.

Where the buttons after being giventhe preliminary polish, are to be mechanically polished and are also to be dyedeither a solidcolor or in a two-tone color effect,'the polishing step last described is usually omitted, and the buttons are soaked in water at room temperature for several hours so that they will better absorb the dye. If the buttons are to be dyed a solid color, they are then immersed in a suitable dye solution and are removed therefrom when the desired shade (which is determined This dyeing operation usually requires from about 5 to 30 minutes. The dye solution may be an ordinary solution of an aniline .or a wood dye, or of any other are immediately immersed in a suitable fixing bath to set the color. The fixing bath employed is-a weak solution of bichromate of potash or other suitable mordant, To thus set the color usually requires about minutes, after which the buttons are removed from the fixing bath, washed and dried in a suitable drying room maintained at a temperature of from '75 degrees to 110 degrees F. After being thoroughly dried,

introduced into a tumbling machine together with suitable material, preferably small wooden .pegs, and such machine is then continuously operated for about an hour. The scum and any foreign material on the surfaces of thereof, will be thus effectively removed and the buttons will also be further polished. Upon re.- moval from the tumbling machine the buttons are finished and need only and packed.

In case the buttons are to be mechanically polished and also dyed in a two-tone color efiect, said'buttons after being preliminarily polished and'soaked in wateras above described, are disposed face up and in a uniform arrangement on trays or other suitable supports. Stencil charts 0 or sheets, the forms of which are dependent upon the designs or mottled efiects desired for the buttons, are then respectively disposed on the trays and over the buttons thereon. The trays with the buttons and stencil sheets thus disposed thereon,

spraying a suitable dye solution, whereupon the faces of the buttons receive partial coatings of the solution, which coatings are fairly heavy and uniform and of a design corresponding to the design of the stencil sheets. A sufiicient amount of terra alba is incorporated in the dye solution to V prevent the same from flowing after being thus sprayed onto the buttons.

dried in the open air and at room 'temperature 5 for a period of several hours, after which they are period of from 3 to 8 by inspection) is obtained.

suitable coal-tar or natural dye. Upon removal from the dye solution, the buttonsthe buttons are whichmay have accumulated the buttons during the dyeing.

to be sorted, inspected are then moved slowly past a device or devices for The buttons are now subjected to the action of a fixing solution to set the-color, and washed in the same manner as de-, scribed above, when the buttons are color.

another coating of dye, which where a two-tone effect is desired, will be the final-coating. Such final coating is thereupon applied by immersing the buttons in a su'table dye solution, and main-- taining the same in such solution for the proper period, after which the buttons are subjected to the action of a fixing bath to set the color of the final coating, washed and dried, all as hereinbefore described in connection with the dyeing of buttons in a solid color. The dried buttons are thereupon polished in tumbling machines first with wax-coated wooden pegs and then with uncoated wooden pegs exactly as above described in respect of buttons which are finished by mechanical polishing and without being dyed, and are then ready to be assorted, inspected and packed.

Where buttons after receiving the preliminary polish, as hereinbefore'described, are to be chemically polished, the procedure is preferably substantially as follows: A solution for treating the buttons is made by thoroughlyQmixing about 50 parts by weight of water, one part by weight of chloride of'lime, and one part by weight of any one of the following substances: carbonate of soda (soda ash), carbonate. This solution is heated toa temperature which is preferably within the limits of 1'70 degrees and 212 degrees F. The buttons are introduced into this heated solution in such a quantity as to be well covered and are maintained in the solution, with occasional stirring, until they have acquired the desired smoothness and lustre. This usually takes from to 30 minutes. The buttons are then removed from said solution and washed, and if they are not to be dyed, are then dried and if desired,

are given a rotating the same for about 1 hour in a tumbling machine with suitable material such as a quantity of dry or unwaxed small wooden pegs; V This last polishing step is not essential, but is often desirable. The buttons are now finished and ready to be sorted, inspected and packed.

If buttons after polishing treatment, are and dyed asolid color, just described, with a solution of a mixture of chloride of lime and soda ash (or bi-carbonateof' soda or potassium carbonate in place of soda ash). to provide the same with a smooth lustrous finish,

' and are then washed. The buttons are thereafter dyed a solid' The buttons are now ready to receive bi-carbonate of soda, and potassium being given the preliminary to be chemically polished they are first treated, as

final polish by When buttons after receiving the preliminary polishing treatment, are to be chemically. polished and dyed to produce a two-tone or mottled color efiect, they are first treated to obtain the smooth lustrous finish or chemical polish, as already 'de-,

scribed, and then washed; The subsequent treatment of thebutton's thus chemically polished, is exactly the same as that in a two-tone color efie t up to and including the steps of fixing, washing and drying the buttons which follow the application thereto of the second and. final coating ofdye, except that .the soaking of the buttonsin water may be, and prefabove described for buttons which are mechanically polished and dyed- 4 -crably is, omitted. The buttons are then jected to the action of suitable material, such as small woodenipegs, in a tumbling achine for inspection and packing.

Buttons which sent a somewhat are chemically polished as herein disclosed, can be effectively dyed to an appreciable depth, either in a solid color or inimulti-tone color effects, with comparative ease. For some reason which is not apparent, the chemical polish thus imparted to the buttons, greatly increases their adaptability for absorbing and retaining the dye. 1

bi-carbonate It is to be understood that my invention as cribed herein is subject to many changes and modifications which entail no departure from the spirit of the invention scope of the appended claims.

Having now described my invention, I claim:

1. The method which consists in subjecting cured articles formed of material consisting principally of casein to the action of a solution of a mixture of chloride of lime and one of the group of soda, bi-

then dyeing said articles.

2. The method which consists in subjecting cured articles formed of material consisting principally of casein to the action of a solution of a mixture of chloride of of materials consisting of carbonate of soda,

3. The method which consists in subjecting cured articles formed of material consisting principally of casein to the action of a solution of a .mixture of chloride of lime and one of the group of materials consisting of carbonate of soda,

.bi-carbonateof soda and potassium carbonate, to predetermined por-- then applying dye only tions of the surfaces of said articles, then sub jecting the articles to the action of a fixing solution, then applying dye to said articles over their entire surfaces, and then again subjecting the articles to the action of a fixing solution.

4. The method which consists in producing an uncured rod by extrusion of an'intimate mix-' ture of materials including casein and-water and in which the casein predominates, cutting a plurality of buttons in their final shape directly from the uncured rod, curing the buttons thus produced, subjecting the cured buttons to a solution of a mixture of chloride of lime and one of the group of materials consisting of carbonate of.

soda, bicarbonate of soda and potassium carbonate, and then dyeing said buttons.

sub- I are mechanically polished presolution of a mixture bonate'of soda, bicarbonate of soda and potaspally of finely divided and which lie within the lime and one of the groupv of soda and potassium carbonate.

25 casein and water, the water content being'less by weight than the casein content, extruding from such mass a homogeneous solid rod, substantially free from voids, substantially uncured and relatively soft, producing a plurality of buttons in their 'ing said buttons in a formaldehyde solution.

9. The method which consists in forming a mass a homogeneous solid rod,

PETER c. 

